BRIEF PROJECT PROFILE ON WELDING ELECTRODE …

1 ESEPL w w w . e u r e k a e l e c t r o d e s . c o m BRIEF PROJECT PROFILE ON WELDING ELECTRODE manufacturing Turn key PROJECT suppliers EUREKA SYSTEMS AND ELECTRODES M A C H I N E R Y D I V I S I O N 11/15A, SELVARAJAPURAM, CHINTHAMANI PUDUR COIMBATORE -641 103, TN, INDIA TEL: +91 422 2687199, 2688065 FAX:+91 422 2681987 ESEPL w w w . e u r e k a e l e c t r o d e s . c o m Introduction We introduce ourselves as a leading WELDING ELECTRODE Solution Provider right from WELDING ELECTRODE Turn key projects to technology know-how. We have at our disposal the state of the art plant & machinery and technology for producing MMAW electrodes (like MS, SS, Cast-iron, Hard facing, Cutting and gouging and etc.) Ours is an ISO 9001-2000 Company managed by professionals to cater the needs of our global customers. We have a very good customer base almost from all the continents.

2 We made this uphill task possible by virtue of our customer support and our effort, skill and efficiency. PROFILE A group of young men under the stewardship of Mr. and associate Mr. , armed with years of technical experience in design, fabrication and commissioning of WELDING electrodes manufacturing machinery and systems, as well WELDING ELECTRODE itself, got together to take the technology to the common man. Eureka Systems was thus formed as a partnership company. From partnership, Eureka Systems grew in to a private limited company in the year 1989. Entrepreneurs with proven talents and stalwarts in their respective fields like paper and textile exports found a common ground in contributing a sizable share of the venture capital and became directors. It was the beginning of the real growth of the company. Their unstinted support elevated Mr. as Managing Director and Mr. S. Ganesan as Technical Director.

3 An over view on WELDING ELECTRODE Industry/Market Though WELDING ELECTRODE is a highly consumable industrial item, the success of this PROJECT depends on marketing, financial planning and production of quality electrodes. The requirement of WELDING ELECTRODE is directly proportional to the steel production in any country. Electrodes are needed both in bulk and small quantity of production. The most important factor in marketing this product is consumer satisfaction and this can be achieved by producing good quality electrodes and selling at the most economical price with the best sales network. So it is you to decide the potential PROJECT which is at your door step to make you successful. ESEPL w w w . e u r e k a e l e c t r o d e s . c o m PRINCIPAL WELDING PROCESSES FUSION NON FUSION HEAT CREATED BY HEAT CREATED BY The above classification shows the position of the Shielded Metal Arc WELDING (Coated ELECTRODE ) among various WELDING process.

4 ELECTRICAL ENERGY CHEMICAL ENERGYCARBON ARC WELDING (Carbon ELECTRODE ) ELECTRON BEAM WELDING ELECTRO SLAG WELDING CHEMICAL ENERGYMECHANICAL ENERGY ELECTRICAL ENERGYFRICTION WELDING ULTRASONIC WELDING RESISTANCE WELDINGFORGE WELDINGOXYACETYLINE NON - FUSION WELDING METAL ARC WELDING (METAL ELECTRODE ) SHIELDED UNSHIELDED PROJECTION WELDINGSPOT WELDING SEAM WELDINGBUTT WELDING RESISTANCE BUTT WELDING FLASH BUTT WELDING RESISTANCE BUTT WELDINGUNSHIELDED SHIELDED OTHER PROCESS PLASMA LASER RESISTANCE BUTT WELDING INERT GAS WELDING SUBMERGED ARC WELDING ATOMIC HYDROGEN SHIELDED METAL ARC WELDING (COATED ELECTRODE ) ESEPL w w w . e u r e k a e l e c t r o d e s . c o m THE PROCESS 1. PREPRATION OF CORE WIRE ELECTRODE quality rimming wire confirming JIS 3503 SWRY 11 with low carbon and low silicon is available in the open market. The wire rod coils are converted to the drawn wire coils of sizes such as , , 4mm and 5mm at the wire drawing plants in house or on job-work basis.

5 It is then straightened and cut in to required lengths by Straightening and Cutting Machine . 2. PREPARATION OF DRY MIX Rutile, Low carbon Ferro Manganese, Cellulose, Titanium Di-Oxide, Mica, Feldspar, quartz, etc., are some of the chemical powders used as the raw materials for the preparation of flux. These chemicals are available world wide and they are weighed accurately as per the technology for each type of electrodes and they are mixed in a dry mixer to get homogeneous mix or can be sourced from Eureka as a readymade flux. 3. PREPARATION OF THE WET MIX. Potassium Silicate is used as the Binding agent. The flux is mixed with Silicate in a correct proportion to obtain a wet mix in a mixer. The Wet mix is then pressed to form a briquettes in a hydraulically operated press in order to load the flux in the flux cylinder of the extruder. 4. APPLICATION OF THE COATING BY EXTRUSION The coating of flux is done by the extrusion press in which the flux fed through a cylinder under pressure.

6 While the wire is fed from the wire magazine of the ELECTRODE press the briquettes are introduced into the extrusion cylinder of the press. During extrusion the core wire is fed one by one from wire feeder and coated with the flux by way of nozzle/die box system incorporated in the extrusion press. The electrodes coming out from the press are tested in an eccentricity tester. The rejected electrodes are taken into the flux stripping machine where the flux is stripped off. The core wire and flux can be re-used. The ELECTRODE coming out from the press is passed through a conveyor to the brushing machine for brushing of holding end and cleaning the same on tip end side for easy striking. After that the electrodes are spread on the collecting tray for air drying and after certain period they are fed into the oven. 5. BAKING OF COATED ELECTRODE After air drying of the coated electrodes they are baked in oven. Depending on the type of ELECTRODE the baking cycle will vary. The moisture content in the ELECTRODE should not exceed 4 percent.

7 ESEPL w w w . e u r e k a e l e c t r o d e s . c o m 6. QUALITY CONTROL Quality control in ELECTRODE making shop calls for, constant checking of the ground ingredients their proportioning and mixing, application procedures, moisture content and drying conditions. In addition, the chemical analysis of the core wire, powders and bonding materials are determined, the coating thickness is measured and the electrodes are tested on trail plates. 7. GRADING AND PACKING The finished electrodes are stored and wrapped in polythene or waxed paper and packed in cartons. Cartons are packed in master cartons as per requirement. The Model of an ELECTRODE Plant and the Name of Machineries DRY MIXER WET MIXER BRIQUETTING PRESS EXTRUDER WIRE FEEDER BRUSHING TIP END CLEANING BAKING OVEN CONVEYOR WIRE STRAIGHTENING AND CUTTING MACHINE ESEPL w w w . e u r e k a e l e c t r o d e s.

8 C o m ESEPL w w w . e u r e k a e l e c t r o d e s . c o m PLANT AND MACHINERIES REQUIRED NOS/CAPACITY/HP/KW MACHINERIES 1 MT 2MT 3MT 4MT 5MT 8MT 10MT WIRE DRAWING MACHINE Not feasible 1 X 160HP 1 x 160HP 2 X 160HP (320HP) 2 X 160HP (320HP) DRY MIXER 1 X 500KG 5HP 1 X 500KG 5HP 1 X 750KG 1 X 1000KG 10HP 1 X 1000KG 10HP 2 X 1000KG 10HP (20HP) 2 X 1000KG 10HP (20HP) WET MIXER 1 X 30KG 3HP 1 X75KG 5HP 1 X 75KG 5HP 1X 100KG 1X 100KG 2 X 100KG (15HP) 2 X 100KG (15HP) CUTTING AND STRAIGHTENING 1 X 120 PCS 5HP 1 X 200 PCS 2 X 200 PCS (17HP) 3 X 200 PCS ( ) 3 X 200 PCS ( ) 4 X 200 PCS (34HP) 5 X 200 PCS ( ) BRIQUETTING PRESS 1 X 2HP 1 X 3HP 1 X 3HP 1 X 5HP 1 X 5HP 1 X 5 HP 2 X 5HP (10HP) EXTRUSION PRESS (Wire feeder, Extruder & Conveyor) 1 X 1 X 1 X 1 X 20HP 1 X 1 X 30HP 2 X (45HP) ELECTRODE NAME PRINTING UNIT 1 X 1 X 1 X 1 X 1 X 1 X 2 X ( ) CONCENTRICITY TESTER 1 1 1 1 1 1 2 BAKING OVEN 1 X 150 C 2HP 12KW 1 X 150 C 2HP 20 KW 1 X 150 C 3HP 26 KW 1 X 150 C 3HP 30 KW 1 X 150 C 3HP 30 KW 2 X 150 C 3HP 30 KW (6HP+ 60KW) 2 X 150 C 3HP 30 KW (6HP+ 60KW) FLUX STRIPPING MACHINE 1 X 3HP 1 X 3HP 1 X 3HP 1 X 3HP 1 X 3HP 1 X 3HP 2 X 3HP (6HP) PACKING TABLE 1 1 1 1 1 2 2 WEIGHING MACHINE 1 X 10 KG 1 X 10 KG 1 X 10 KG 1 X 10 KG 1 X 10KG 2 X 10KG 2 X 10KG HAND SEALING PRESS 1 1 1 1 2 3 4 SHRINK PACKING MACHINE 1 X 9KW 1 X 9KW 1 X 9KW 1 X12KW1 X 12KW 2 X 9KW (18KW) 2 X 9KW (18KW)

9 STRAPPING MACHINE 1 X 1 X 1 X 1 X 1 X 2 X ( ) 2 X ( ) CUT WIRE STAND 3 5 7 10 10 12 15 METAL TRAYS 300 400 500 800 1000 1600 2000 TOTAL HP AND KW REQURED 31HP 21KW 29KW 29KW 235HP 39KW 237HP 39KW 434HP 78KW 471HP 78KW Additional Requirement (for handling and testing)- Optional) NOS/CAPACITY/HP/KW MACHINERIES 1 MT 2MT 3MT 4MT 5MT 8MT 10MT PALLET TRUCK 1 X 2MT 1 X 2MT 1 X 2MT 1 X 2MT 1 X 2MT 1 X 5MT 1 X 2MT 1 X 5MT 1 X 2MT 1 X 5MT WEIGHING MACHINE 1X300KG 1X300KG 1X300KG 1X300KG 1X300KG 1X300KG 1X300KG CHEMICAL LABORATORY 1 SET 15KW 1 SET 15KW 1 SET 15KW 1 SET 15KW 1 SET 15KW 1 SET 15KW 1 SET 15KW PHYSICAL LAB 1 SET 5HP 1 SET 5HP 1 SET 5HP 1 SET 5HP 1 SET 5HP 1 SET 5HP 1 SET 5HP WELDING TRANSFORMER AC 1X 21 KVA 1X 21 KVA 1X 21 KVA 1X 21 KVA 1X 21 KVA 1X 21 KVA 1X 21 KVA WELDING TRANSFORMER DC 1X 21 KVA 1X 21 KVA 1X 21 KVA 1X 21 KVA 1X 21 KVA 1X 21 KVA 1X 21 KVA MACHINE SHOP 1 SET 15HP 1 SET 15HP SET 15HP TOTAL HP 5HP 57KW 5HP 57KW 5HP 57KW 5HP 57KW 20HP 57KW 20HP 57KW 20HP 57KW ESEPL w w w.

10 E u r e k a e l e c t r o d e s . c o m 1 MT PLANT LAYOUT LAND AND BUILDINGS The land and building requirement depends on the capacity of the plant as well the facilities required. IN SQUARE FEET Capacity For wire drawing For ELECTRODE conversion Storage Laboratory Total 1MT - 3000 1000 1000 5000 2MT - 4000 2000 1000 7000 3MT - 5000 3000 1000 9000 4MT 5000 6000 4000 1000